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My drills came in from Hong Kong today and the box of bulkhead fittings came in yesterday

So I had to choose between doing some homework or drilling a tank or two.

So here are some pics and the how to:

The first step is to make a jig and backing board out of some scrap wood. I cut that strip off the edge so that I could get the hole as close to the top of the tank as possible. This meant that I would need to trim the frame, but I wanted the water level way up there. (Drilling an unknown bottom is not wise.)

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Step two is to clamp the jig and backer to the tank. Here you can see why the backer is important. It distributes the stress from the clamp. It also catches the disc at the end of drilling, and minimizes punch through at the end of the operation.